Beneficiation of saline minerals

ABSTRACT

A process is provided for recovering a saline mineral from an ore containing the saline mineral and impurities. In one aspect, the process generally includes the steps of separating a first portion of impurities from the ore by density separation, electrostatically separating a second portion of impurities from the ore, and magnetically separating a third portion of impurities from the ore. The process can further include the steps of crushing the ore and dividing the crushed ore into a plurality of size fractions before the above-referenced separating steps. In another aspect, the process includes the steps of calcining the ore and subsequently separating a first portion of impurities by density separation. Indirect heating may be utilized for the calcining process and, preferably, calcining gases are recycled and utilized for heating fluidizing another portion of ore. Water vapor may be condensed from the calcining gas and utilized for other purposes.

REFERENCE TO RELATED APPLICATIONS

This application is filed under 35 U.S.C. §371 based on PCT/US94/05918, filed on May 25, 1994, which is a CIP of U.S. patent application Ser. No. 066,871, filed on May 25, 1993, now U.S. Pat. No. 5,470,554.

FIELD OF THE INVENTION

The present invention relates generally to the beneficiation of saline minerals and, more specifically, trona. The invention further relates to a dry process for recovering saline minerals from an ore containing saline minerals and impurities.

BACKGROUND OF THE INVENTION

Many saline minerals are recognized as being commercially valuable. For example, trona, borates, potash and sodium chloride are mined commercially. After mining, these minerals need to be beneficiated to remove naturally occurring impurities.

With regard to trona (Na₂ CO₃.NaHCO₃.2H₂ O), high-purity trona is commonly used to make soda ash, which is used in the production of glass and paper. Naturally-occurring trona, or crude trona, is found in large deposits in the western United States, such as in Wyoming and California, and also in Egypt, Kenya, Botswana, Tibet, Venezuela and Turkey. Crude trona ore from Wyoming is typically between about 80% and about 90% trona, with the remaining components including shortite, halite, quartz, dolomite, mudstone, oil shale, kerogen, mica, nahcolite and clay minerals.

The glass and paper making industries generally require soda ash produced from trona having a purity of 99% or more. In order to obtain such a high purity, wet beneficiation processes have been used. Such processes generally involve crushing the crude trona, solubilizing the trona, treating the solution to remove insolubles and organic matter, crystallizing the trona, and drying the trona which may subsequently be calcined to produce soda ash. Alternatively, the crude trona can be calcined to yield crude sodium carbonate, which is then solubilized, treated to remove impurities, crystallized and dried to produce sodium carbonate monohydrate.

Not all industries which use trona require such a highly purified form of trona. For example, certain grades of glass can be produced utilizing trona having less than 97% purity. For this purpose, U.S. Pat. No. 4,341,744 discloses a dry beneficiation process which is less complex and less expensive than the above-described wet beneficiation process. Such a dry beneficiation process generally includes crushing the crude trona, classifying the trona by particle size, electrostatically separating certain impurities, and optionally magnetically separating other impurities. Such a process can yield trona having up to about 95% to 97% purity, depending on the quantity and type of impurities present in the crude trona ore. The lower resulting purities of known dry processes is partially due to the presence of impurities, such as shortite and halite, which have similar electrostatic and magnetic properties as the trona. Further, halite has a similar density as the trona and, therefore, is difficult to remove even utilizing known wet density separation processes.

There are uses for trona, for example, in certain applications in the glass industry, requiring a purity of at least 97%, yet not needing a purity over 99%. The known dry beneficiation processes typically do not consistently produce such a purity. Consequently, these industries generally use trona purified by the more expensive and complex wet beneficiation processes.

Accordingly, it is an object of the present invention to provide a dry process for the beneficiation of saline minerals and in particular, trona, resulting in higher purities than existing dry beneficiation processes and which is simpler and less expensive than known wet beneficiation processes.

SUMMARY OF THE INVENTION

The present invention is embodied in a process for recovering a high-purity saline mineral from an ore containing the saline mineral and impurities. In one aspect of the present invention, the process generally includes separating a first portion of impurities from the ore by a density separation method, electrostatically separating a second portion of impurities from the ore, magnetically separating a third portion of impurities from the ore.

In one embodiment, the density separation step can include air tabling or dry jigging to separate impurities having a different density than the saline mineral. In another embodiment, the process of the present invention is used for beneficiating trona from an ore containing trona and impurities. In this embodiment, the first portion of impurities removed by the density separation step comprises shortite.

In another embodiment of the present invention, a process is provided for the production of purified soda ash for production of caustic soda by the lime-soda process. The process generally includes the steps of separating a first portion of impurities from a trona-containing ore by a density separation method, electrostatically separating a second portion of impurities from the ore, magnetically separating a third portion of impurities from the ore. The product of the above-mentioned separation processes is used to produce caustic soda. The process further includes solubilizing aluminum hydroxide in bauxite by contacting the bauxite with the caustic soda to produce a solution and recovering alumina from the solution.

In another aspect of the present invention, a process is provided which includes calcining the saline mineral prior to density separation. The process generally includes calcining the ore to alter the apparent density of the saline mineral and separating a first portion of impurities from the calcined ore by density separation to produce a recovered saline mineral. This process is particularly suitable for separating impurities which have densities similar to the density of the saline mineral prior to calcination, but which have different apparent densities after calcination. In one embodiment, the saline mineral comprises trona and the first portion of impurities comprises halite. The process also improves the separation of a saline mineral from other impurities by widening the difference in apparent densities between the saline mineral and such other impurities.

In yet another aspect of the present invention, a process is provided for effectively removing impurities from about a -65 mesh size fraction. The process generally comprises the steps of sizing the ore to generate about a -65 mesh fraction and about a +65 mesh fraction and separating iron from the -65 mesh fraction to produce a first recovered portion. In one embodiment, the separating step comprises a wet separation process, such as the slush process. In another embodiment, the separating step comprises magnetic separation. In addition to iron, shaley components, such as dolomitic and oil shales, may also be removed during the separating step. Preferably, a second portion of impurities is separated from the +65 mesh fraction to produce a second recovered portion, and the first and second recovered portions are combined to produce a recovered saline mineral.

In another aspect of the present invention, a novel process for calcining saline minerals is provided. The process generally comprises heating the saline mineral in a calcining vessel above its calcining temperature with a heat source to calcine the saline mineral, wherein said heat source is not in direct fluid communication with said saline mineral. The saline mineral may comprise, for example, trona. In one embodiment, the heating step includes heating a fluid (e.g., steam) and bringing the fluid into thermal communication with the calcining vessel (e.g., utilizing a steam coil heat exchanger positioned within the interior of the vessel). In another embodiment, the calcining gases produced by the calcining process are recycled back to the vessel inlet, such as to provide a medium for fluidizing. To accomplish this, at least a portion of calcining gas must be removed from the process stream to accommodate for the gas produced by the calcining process.

In yet another embodiment, water vapor may be removed from the calcined gas to reduce significantly the amount of gas emitted from the system. For example, water may be condensed from the calcining gas utilizing a scrubber, which also aids in removal of particulates from the gas stream.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic representation of one embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The processes of the present invention are designed to recover saline minerals from naturally occurring ores to produce commercially valuable purified minerals. As used in the mineral processing industry, the term "saline mineral" refers generally to any mineral which occurs in evaporite deposits. Saline minerals that can be beneficiated by the present process include, without limitation, trona, borates, potash, sulfates, nitrates, sodium chloride, and preferably, trona.

The purity of saline minerals within an ore depends on the deposit location, as well as on the area mined at a particular deposit. In addition, the mining technique used can significantly affect the purity of the saline minerals. For example, by selective mining, higher purities of saline minerals can be achieved. Deposits of trona ore are located at several locations throughout the world, including Wyoming (Green River Formation), California (Searles Lake), Egypt, Kenya, Venezuela, Botswana, Tibet and Turkey (Beypazari Basin). For example, a sample of trona ore from Searles Lake has been found to have between about 50% and about 90% by weight (wt. %) trona and a sample taken from the Green River Formation in Wyoming has been found to have between about 80 and about 90 wt. % trona. The remaining 10 to 20 wt. % of the ore in the Green River Formation sample comprised impurities including shortite (1-5 wt. %) and the bulk of the remainder comprises shale consisting predominantly of dolomite, clay, quartz and kerogen, and traces of other impurities. Other samples of trona ore can include different percentages of trona and impurities, as well as include other impurities.

In the first aspect, the present process includes removing a first portion of impurities from an ore containing saline minerals by a density separation method. Density separation methods are based on subjecting an ore to conditions such that materials of different densities physically separate from each other. Thereby, certain impurities having a different density than the desired saline mineral can be separated. The density separation step of the present invention is most preferably a dry process, however, wet density separation processes, such as heavy media separation, can be used as well. In dry density separation processes, the need for processing in a saturated brine solution, solid/brine separation, and drying of the product is eliminated. Consequently, the process according to the present invention is much cheaper and less complex. Any known density separation technique could be used for this step of the present invention, including air tabling or dry jigging.

As discussed above, density separation is conducted by subjecting an ore to conditions such that materials of different densities separate from each other. The mineral stream having materials of varying densities is then separated by a first or rougher pass into a denser and a lighter stream, or into more than two streams of varying densities. Typically, in the case of beneficiating trona, trona is recovered in the lighter stream. The purity of a saline mineral recovered from density separation can be increased by reducing the weight recovery of the recovered stream from the feed stream. At lower weight recoveries, the recovered stream will have a higher purity, but the rougher stage process will also have a reduced yield because more of the desired saline mineral will report to the impurity stream. Such a "high purity" process may be beneficial in that it requires less subsequent processing (e.g., separation) of the ore and, in addition, may be of higher value because it can be used in other applications where high purity saline minerals are required.

In the case of beneficiating trona, for example, the weight recovery (weight of trona recovered/weight of trona in the feed stream) from the density separation step is between about 65% and about 95%. More preferably, the weight recovery is between about 70% and about 90% and, most preferably, the weight recovery is about 80%.

In an alternative embodiment, the impurity stream from density separation can go through one or more scavenger density separation step(s) to recover additional trona to improve the overall recovery. The scavenger separation is similar to the above-described density separation step. The scavenger step recovers a portion of the impurity stream from the rougher pass having the saline mineral in it and combines that portion with the above-described recovered stream to increase the overall yield from density separation or recycles it to other steps in the process, with or without further size reduction.

In a further alternative embodiment, the recovered stream from the rougher pass density separation can go through one or more cleaning density separation steps to further remove impurities from the recovered stream and improve the purity of the final product. The cleaning step is similar to the above-described density separation process in that impurities are removed from the stream by density separation. In both scavenging and cleaning passes, the feed stream into those passes can undergo further size reduction, if desired, for example, to achieve higher liberation.

With regard to the beneficiation of trona, which has a density of 2.14, impurities that are removed during the density separation step of the present invention include shortite, having a density of 2.6, dolomite, having a density of 2.8-2.9 and pyrite, having a density of 5.0. Each of these is separable from the trona ore because of differences in density from trona. By practice of the present invention, of the total amount of shortite, dolomite, pyrite and, if present, potentially valuable heavy minerals in the trona ore, the density separation step can remove at least about 10 wt. % and more preferably, about 50 wt. %, and most preferably, about 90 wt. % of the heavy impurity.

In an alternative embodiment, impurities removed during the density separation process can be recovered as a product for commercial use. For example, in the beneficiation of trona, the impurities removed during the air tabling step can comprise as much as 90% shortite. Such shortite may be acceptable, for example, for certain applications in the glass industry. The acceptability of the shortite in the glass industry will depend upon the consistency and the relative lack of iron in the product. In addition, for some trona deposits, potentially valuable heavy minerals may be present. Such minerals can be separated in the method and recovered.

The present invention further includes removing a second portion of impurities by an electrostatic separation method. Electrostatic separation methods are based on subjecting the ore to conditions such that materials of different electrical conductivities separate from each other. The electrostatic separation of the present invention can be accomplished by any conventional electrostatic separation technique. U.S. Pat. No. 4,341,744 discloses standard electrostatic separation processes suitable for use in the present invention in col. 4, line 62 through col. 6, line 32, which is incorporated herein by reference in its entirety. As discussed in the above-identified patent, saline mineral ore particles are first differentially electrified and then separated into a recovered stream from an impurity stream by various electrostatic separation processes.

As noted above for the density separation step, the impurity stream from the rougher pass of an electrostatic separation process can go through a scavenger step to improve the overall recovery. The scavenger step recovers a saline mineral-containing portion of the impurity stream from the rougher pass through electrostatic separation and combines it with the above-described recovered stream to increase the overall yield of the electrostatic separation step or otherwise cycles it to other steps in the process. Furthermore, the recovered stream from the rougher pass of the electrostatic separation can go through one or more electrostatic cleaning steps to further remove impurities from the recovered stream and improve the purity of the final product.

For example, electrostatic separation can be used to separate trona from impurities having a higher electrical conductivity, such as shale, mudstone or pyrite. It should be appreciated, however, that electrostatic separation could also be used to separate impurities that have a lower electrical conductivity than the saline mineral being recovered. By practice of the present invention, utilizing electrostatic separation can remove at least about 10 wt. %, more preferably, about 50 wt. %, and most preferably, about 90 wt. % of the more conductive mineral impurities from the is material being treated by electrostatic separation.

The present process further includes a magnetic separation step which subjects the ore to conditions such that materials of different magnetic susceptibilities separate from each other into a recovered stream and an impurity stream. The magnetic separation step can be accomplished by any conventional technique, such as induced roll, cross-belt, or high intensity rare earth magnetic separation methods. Preferably, induced roll is used in the present invention for the finer fractions and high intensity rare earth magnets are used for the coarser fractions. With regard to the beneficiation of trona, typical impurities that can be removed during the magnetic separation step include shale which has a higher magnetic susceptibility than trona. By practice of the present invention, the use of an induced roll magnetic separation technique can remove at least about 5 wt. %, more preferably, about 50 wt. %, and most preferably about 90 wt. % of the shale from the material being treated by magnetic separation.

As noted above for the density and electrostatic separation steps, the impurity stream from the rougher pass of the magnetic separation process can go through one or more scavenger steps to improve the overall recovery. The scavenger step recovers a portion of the impurity stream from the rougher pass through magnetic separation and combines it with the above-described recovered stream or recycles it to the process with or without further size reduction to increase the overall yield of the magnetic separation step. Furthermore, the recovered stream from magnetic separation can go through one or more magnetic cleaning steps to further remove impurities from the recovered stream and improve the purity of the final product.

It should be appreciated that the above-identified process steps could be performed in any order. Preferably, however, the density separation is performed first, followed by electrostatic separation and finally magnetic separation.

In a further embodiment of the present invention, the saline mineral-containing ore can be crushed to achieve liberation of impurities prior to the separation steps. The crushing step of the present invention can be accomplished by any conventional technique, including impact crushing (e.g., cage or hammer mills), jaw crushing, roll crushing, cone crushing, autogenous crushing or semi-autogenous crushing. Autogenous and semi-autogenous crushing are particularly beneficial because the coarse particles of ore partially act as the crushing medium, thus requiring less cost in obtaining grinding media. Moreover, because saline minerals are typically soft, these methods are suitable for use in the present process. In addition, these two crushing methods allow for the continuous removal of crushed material and high grade potentially saleable dust.

In general, crushing to smaller particle size achieves better liberation of impurities and thus, improved recovery. However, if the particle size after crushing is too fine, there may be adverse effects upon subsequent separation steps. In addition, over-crushing is not needed for many applications of the present invention and merely increases the costs associated with the crushing step. It has been found that acceptable liberation for the present process can be achieved by crushing the ore to at least about 6 mesh. Preferably, the particle size range after crushing is from about 6 to about 100 mesh and, more preferably, from about 6 to about 65 mesh.

In another embodiment of the present invention, the ore is sized into size fractions prior to the separation steps. Each size fraction is subsequently processed separately. In general, the narrower the range of particle size within a fraction, the higher the efficiency of removal of impurities. On the other hand, a larger number of fractions will increase the efficiency, but may increase the cost of the overall process. The use of between 3 and 10 fractions has been found to be acceptable. Preferably, the number of fractions is between 4 and 10 and, more preferably, the number of fractions is 8. Any conventional sizing technique can be used for the present process, including screening or air classification. For dividing into 8 fractions, the fractions typically have the following particle size ranges: 6 to 8 mesh; 8 to 10 mesh; 10 to 14 mesh; 14 to 20 mesh; 20 to 28 mesh; 28 to 35 mesh; 35 to 48 mesh; 48 to 65 mesh (Tyler mesh).

In yet another embodiment of the present invention, the ore is dried prior to the separation processes set forth above. The drying step removes surface moisture from the ore to better enable the ore to be separated. Drying can be accomplished by any conventional mineral drying technique, including rotary kiln, fluid bed or air drying. The ore can be dried to less than about 2%, and preferably less than about 1% surface moisture content. During the drying process, it is preferred that the saline mineral is not raised to such a temperature for such a period of time that is it calcined. In the case of trona, the drying temperature should remain below about 40 degrees centigrade to avoid calcination.

In still another embodiment of the present invention, a de-dusting step is added to the basic beneficiation process to remove fines before the electrostatic and magnetic separation steps. De-dusting can be particularly important before electrostatic separation because the dust can otherwise interfere with effective electrostatic separation. Such a de-dusting step can be conducted before, during or after one or more of the crushing, sizing and/or density separation steps. The fines produced during the processing of trona are relatively high purity trona and are useful in several industrial applications. For example, trona recovered by de-dusting can have a purity of greater than about 94%, preferably greater than about 96% and more preferably greater than about 98%. Fines can be collected in de-dusting steps by use of a baghouse, or other conventional filtering device, and sold as purified trona without further processing.

The present invention provides a process for the separation of saline minerals from an ore utilizing a dry beneficiation technique, resulting in a high purity product, typically greater than 85% purity, produced at low cost compared to wet beneficiation processes. Utilizing the above-described process, trona having about 98.8% purity from an ore containing 90% trona has been obtained, compared to less than about 97% purity for the prior art dry beneficiation processes. The purity of recovered product can be greater than about 97%, preferably greater than about 97.5%, and more preferably greater than about 98%. In addition, by utilizing selective mining techniques and lower weight recoveries for the separation steps, higher purities can be obtained.

Utilizing the process of the present invention, recoveries of greater than about 55% can be obtained. More preferably, recoveries are greater than about 65% and, most preferably, greater than about 75a. In the case of trona, the resulting trona product can be used in many applications, especially those requiring a purity of about 97.5% or greater, such as in certain areas of the glass industry.

In the second aspect of the present invention, a process is provided whereby impurities having the same or similar density, magnetic properties and/or electrostatic properties as a saline mineral in an ore can be effectively removed. As used herein, the term "saline minerals" has the same meaning as it is used in the description of the first aspect of the present invention. The process recognizes and relies on the fact that the apparent density of saline minerals, such as trona, changes during calcining, while the apparent densities of many impurities remain relatively constant during calcining. A reduction in apparent density of the saline mineral allows the impurities to be removed utilizing density separation, even if the pre-calcined density of the trona is the same as or similar to that of the impurity.

Accordingly, the second aspect of the present invention comprises a process for recovering a saline mineral from an ore containing the saline mineral and impurities. A schematic diagram of a process embodying the second aspect of the present invention is illustrated in the accompanying FIGURE. The process may be performed utilizing each of the illustrated process or, alternatively, bypassing some of the illustrated processes. The process generally comprises the steps of calcining the ore to alter the apparent density of the saline mineral and separating a first portion of impurities from the calcined ore by density separation to produce a recovered saline mineral. As noted above, the impurities may have a density which is similar to the density of the un-calcined saline mineral, but which is sufficiently different than the apparent density of the calcined saline mineral to be readily susceptible to density separation.

The calcining step can be performed utilizing any appropriate calcining process. For example, direct heating utilizing a rotary kiln or fluidized bed reactor can be utilized. In a preferred embodiment, the calcining step is performed utilizing an indirect heating process in a calcining vessel such as a fluidized bed reactor at a temperature of at least about 120° C. In the indirect heating process, the combustion gases from the heat source are not in direct fluid communication with the ore containing the saline mineral, but rather provide heat to the ore by conduction through, for example, heating coils, as described in more detail below. In one embodiment, the calcining occurs at least about 140° C. with a 20 minute residence time within a fluidized bed reactor. Other calcining times and temperatures may also be utilized as is known in the art.

The density separation step is based on subjecting the ore to conditions such that materials of different apparent densities physically separate from each other. In the case of beneficiating uncalcined trona, having a density of about 2.14, density separation is relatively effective in removing shortite, having a density of about 2.6; dolomite, having a density of about 2.8-2.9; and pyrite, having a density of about 5.0, as described above in more detail. On the other hand, density separation of uncalcined trona is generally not effective in separating impurities having a density close to that of uncalcined trona, such as halite, which has a density of about 2.17.

Therefore, in accordance with the second aspect of the present invention, it has been discovered that the calcining process reduces the apparent density of saline minerals. In the case of trona, the apparent density reduces to less than about 2.0. It is believed that such reduction in apparent density is caused by the formation of voids within the trona particles without a significant change in the particle size. Thus, when a calcined trona particle is subjected to density separation, such as on an air table, the particle will behave approximately as if it were a particle of the same shape with a uniform actual density lower than the actual density of calcined trona. With such a reduction in the apparent density of calcined trona, impurities such as halite can be separated utilizing density separation methods based upon differences in apparent density. Furthermore, the density separation of other impurities, such as shortite, dolomite and pyrite is significantly improved due to the larger difference between the apparent densities of the trona and these impurities. The density separation step may remove as much as 50%, preferably 75%, and more preferably 90%, of these impurities. The resulting purity of the trona is preferably at least about 95%, and more preferably about 98%.

As noted above in more detail, the density separation step is preferably a dry process; however, wet density separation processes such as heavy media separation may be used as well. Any known density separation technique could be used for this step of the invention, including air tabling or dry jigging. Further details of the density separation step are set forth above in the description of the first aspect of the invention.

In one embodiment of the second aspect of the invention, as noted above, the step of heating the ore for calcining includes indirect heating which comprises the steps of heating a fluid and bringing the heated fluid into thermal communication with the ore in the calcining vessel. This step can be accomplished utilizing a heat source which provides the heated fluid to coils positioned within the interior of the calcining vessel. In one embodiment, the heat source is a steam boiler and the fluid is steam. Alternatively, the fluid may comprise oil or any other appropriate medium. The step of heating the fluid can comprise the steps of combusting an energy source to produce heat and combustion gas, transferring at least a portion of the heat to the fluid, and directing at least a portion of the combustion gas through a combustion gas outlet which is not in direct fluid communication with the calcining vessel.

The utilization of indirect heating for calcining the saline mineral provides significant benefits in that it significantly reduces the amount of gas flowing through the fluidized bed because no combustion gas flows through the bed. In this manner, a significantly lower amount of particulates from the ore are entrained and need to be removed from exhaust gas from the calcining operation. More specifically, the amount of gas required for fluidization is about 80% less than the amount of gas produced during the combustion necessary to produce sufficient heat for the calcining process (e.g., utilizing natural gas in a steam boiler). Accordingly, by utilizing a source of gas for fluidization which is different than the combustion gases, a smaller amount of fluidizing gas can be used. Further, the smaller amount means that the fluidizing gas will flow at lower velocities, thereby potentially reducing particulate entrainment even further. In addition, less fluidizing gas means that less gas needs to be scrubbed for particulates before emission, thereby reducing the costs of the calcining process.

It is well known that the calcining process produces calcining gas having a significant amount of water vapor. For example, calcining three moles of trona produces five moles of water and one mole of carbon dioxide. In order to reduce the amount of calcining gas exiting the system, the process may further comprise the step of condensing at least a portion of the water vapor from the calcining gas by, for example, cooling the calcining gas. Such condensation step will reduce the calcining gas volume by as much as 5/6ths, thereby reducing the amount of calcining gas which must be treated. In addition to reducing the volume of gas exiting the system, the condensing step also has a scrubbing effect on the calcining gas by removing particulates from the calcining gas. It is believed that the amount of particulates removed is proportional to the amount of gas removed (i.e., as much as 5/6ths or more). It is estimated that the particulate emission from a process for calcining trona ore in a direct-fired rotary calciner is typically about 6 lbs/ton of feed. By practice of the present process, including indirect calcination and condensing water from calcining gas, the particulate emissions from calcination of trona ore can be less than about 3 lbs/ton of feed, more preferably less than about 1.5 lbs/ton of feed and most preferably less than about 1 lbs/ton of feed.

In a preferred embodiment, the condensing step for condensing water from gas produced during calcining comprises two stages. In the first stage, a small amount (e.g., less than about 5%) of the water vapor within the calcining gas is condensed to significantly reduce the particulate content of the gas. The first stage can be performed utilizing a water-cooled condenser, such as a tubed condenser. In the second stage, as much as 80% of the water vapor is condensed. Because of the reduction in particulate content resulting from the first stage, the water condensed from the second stage is essentially distilled water grade. A third stage may be added to further scrub particulates from the gas. For example, a high-efficiency venturi scrubber or electrostatic precipitator may be used.

The water which is removed during the condensing steps can be utilized for other processes. For example, the condensed water may be cooled (e.g., using air coolers) and then recycled and used as the cooling medium to condense further water vapor from the calcining gas by bringing the cooled water into thermal communication with the pre-condensed calcining gas. Further, the condensed water could be utilized for wet separation processes in other areas of the facility such as for treating fines, as described below. The condensed water may also be treated and utilized for almost any other appropriate purpose, such as for general water usage in the facility (e.g., for cleaning, drinking water, etc.).

Calcining gas which is produced during the calcining process may be removed from the calcining vessel through a calcining gas outlet, and at least a portion of the calcining gas (proportional to the amount of CO₂ produced in the calcining process) may be expelled through a stack. The expelled gas is preferably heated prior to exiting through the stack to inhibit condensation and plume formation at the stack outlet. For example, the expelled gas can be mixed with hot combustion gas from heating fluid for indirect calcination.

Another portion of the calcining gas may be recycled back to the inlet of the calcining vessel and utilized for heating and fluidizing additional ore for calcining. Preferably, this gas is recycled after the above-noted condensation step, thereby resulting in dry CO₂ as the heating and fluidizing medium. The recycled gas may be heated (e.g., by steam coils) in order to bring the gas up to a temperature prior to entry into the calcining vessel. In one embodiment, the recycled gas temperature is between about 120° C. and about 200° C., and is preferably about 140° C. This recycling of gas is beneficial in that it utilizes latent heat within the calcining gas as part of the energy required for calcining, rather than heating ambient temperature gas up to calcining temperature. Further, such recycling reduces the gas requirements and emissions of the process by eliminating the need for fresh gas.

In another embodiment of the second aspect of the present invention, the process further includes removing a second portion of impurities by a magnetic separation method such that materials of different magnetic susceptibilities separate from each other into a recovered stream and an impurity stream. With regard to the beneficiation of trona, typical impurities that can be removed during the magnetic separation step include shaley components, such as dolomitic shale and oil shale, iron associated with the shaley components, complex iron silicates, iron-bearing carbonates, as well as other impurities having different magnetic susceptibilities. Such shaley components typically have a higher magnetic susceptibility than trona. Further details of the magnetic separation step are set forth above in the description of the first aspect of the invention.

It should be appreciated that the magnetic separation step could be performed at any point in the separation process. For example, magnetic separation may occur prior to calcining and/or prior to the density separation step. Furthermore, the ore may be subjected to density separation prior to calcining to remove some impurities and then subjected to another density separation step after calcining to remove more impurities. Other separation techniques, such as electrostatic separation, could also be incorporated into the second aspect of the invention.

In another embodiment of the present invention, the saline mineral-containing ore is crushed to achieve liberation of impurities prior to the calcining step. Preferably, the ore is crushed to at least about 6 mesh during the crushing step. Further details of the crushing step are set forth above in the description of the first aspect of the invention.

After crushing, fines are preferably removed from the ore. In one embodiment, particles having a size less than about 200 mesh are removed and processed separately from the remaining size fractions. Such fines are removed because they are typically not processable utilizing dry separation processes, such as air tabling. The about -200 mesh fraction subsequently can be treated utilizing a wet separation process, such as the slush process. The slush process generally comprises mixing the calcined trona fines in a saturated brine solution at between 40° C. and 80° C. to convert the anhydrous sodium carbonate to monohydrate form. The slurry is then heated to between 112° C. and 120° C. under pressure to convert back to anhydrous form. The slurry is then cooled, causing the sodium carbonate to crystallize back to the monohydrate form. The crystallization process squeezes out impurities and forms coarse sodium carbonate particles. The particles are then screened and washed to remove impurities. Subsequent calcining of the particles converts the sodium carbonate back to anhydrous form.

In addition to processing the -200 mesh fraction as discussed above, saline mineral particles falling between about 65 mesh and about 200 mesh are typically not able to be readily separated from impurities in that size fraction utilizing conventional dry density separation processes, such as air tabling. This aspect includes separately processing the 65×200 fraction to remove iron and shale. Surprisingly, it has been found that iron impurities are concentrated in about the -65 fraction of saline mineral-containing ore and in particular, trona-containing ore. Thus, by removing the -65 fraction and processing it separately, a significant portion of the iron is removed from the ore. The 65×200 fraction can be wet processed, as described above, or can be magnetically separated to remove shaley components and iron associated therewith. After separating the impurities, the 65×200 fraction can be recombined with the beneficiated larger size fractions, or it can be used for a different purpose more suited to its particle size and purity.

The +65 mesh particles are sized into size fractions before the density separation step. Each size fraction is subsequently processed separately. In general, the narrower the range of particle size within a fraction, the higher the efficiency of removal of impurities during the density separation step. On the other hand, narrow size fractions requires a large number of fractions which may increase the cost of the overall process. Further details of the sizing step are set forth above in the description of the first aspect of the invention.

The number of size fractions required for a particular separating step depends in part on the difference in properties between the minerals sought to be separated. For example, in the density separation step, the larger the difference between the densities of the saline mineral and the impurity, the smaller the number of size fractions required (i.e., the larger the allowed size variation within a particular fraction). In the case of beneficiating trona, the calcining step increases the difference between the apparent density of the trona and at least some of the impurities. Accordingly, it is believed that the process according to the second aspect of the invention will allow the use of between 3 and 10 size fractions. In one embodiment, the process utilizes as few as 5 size fractions, each having a wider range of particle size within the fraction. Such reduction in the number of fractions decreases the cost of the overall process. In addition, or alternatively, it is believed that the process according to the second aspect of the present invention may be utilized to produce a higher grade product and/or higher recoveries.

It has been found that the above-identified processes for beneficiating trona are also particularly adaptable for use in the production of caustic for use in alumina production. By transporting beneficiated and calcined trona ore to alumina processing facilities and producing caustic from the beneficiated trona, the total cost for caustic can be significantly below that of caustic currently used in the alumina industry. For this application, the trona-containing ore is beneficiated and the resulting beneficiated trona is calcined to produce soda ash (Na₂ CO₃). The soda ash is then converted to caustic soda by conventional processes at an alumina plant and can then be used in conventional alumina processing. For example, the Bayer process can be used in which caustic soda is mixed with bauxite to solubilize the aluminum hydroxide in the bauxite to produce a sodium illuminate solution. Alumina hydrate can be precipitated from the solution and calcined to remove water therefrom.

The foregoing description of the present invention has been presented for purposes of illustration and description. Furthermore, the description is not intended to limit the invention to the form disclosed herein. Consequently, variations and modifications commensurate with the above teachings, and the skill or knowledge of the relevant art, are within the scope of the present invention. The embodiment described hereinabove is further intended to explain the best mode known for practicing the invention and to enable others skilled in the art to utilize the invention in such, or other, embodiments and with various modifications required by the particular applications or uses of the present invention. It is intended that the appended claims be construed to include alternative embodiments to the extent permitted by the prior art.

EXAMPLES 1-8

Eight samples of trona-containing ore from Bed 17 of the Green River Formation in Wyoming were beneficiated in accordance with the first aspect of the present invention. Each of the samples was crushed to -10 mesh on a roll crusher. The samples were allowed to air dry until they attained a constant weight (about 24 hours). The samples were subsequently screened at 20 mesh, 35 mesh, 65 mesh and 150 mesh Tyler. Each of the four 150 plus size fractions was then subjected to electrostatic separation to generate a conductive and non-conductive stream. The non-conductive stream resulting from the electrostatic separation regime for each of the size fractions was subjected to high intensity magnetic separation to generate a magnetic and non-magnetic stream. The resulting non-conductive/non-magnetic streams from each of the size fractions were then subjected to a density separation step. A heavy liquid separation was used for density separation in these examples. The heavy liquid used was a mixture of acetylene tetrabromide and kerosene. Since the saline mineral being beneficiated was trona, having a specific gravity of 2.14; the major impurity was shortite, having a specific gravity of 2.6; and other impurities having a specific gravity lighter than 2.0 were present, density separations were made at specific gravities of 2.0 and 2.3 to generate a 2.0×2.3 fraction which is the trona fraction.

The data generated from the foregoing beneficiation processes is shown in Tables 1-8. As can be seen from the Tables, the purity of trona recovered ranged from 95.3 in Example 2 to 98.8 in Example 3 (shown as soluble % in 2.0×2.3 S.G. separation). In addition, the effectiveness of the density separation in improving trona purity can be seen by comparing the Soluble % in the "Plus 65 mesh trona" line (before density separation) with the Soluble % in the "2.0×2.3 S.G." line (after density separation).

                  TABLE 1                                                          ______________________________________                                                  Weight Percent                                                                       Bene- Assay                                                              Frac-                                                                               Sam-   ficiated                                                                               Insoluble                                                                              Soluble                                   Fraction   tion   ple    Product                                                                              %    Distr.                                                                              %    Distr.                           ______________________________________                                         Electrostatic and Magnetic Separation of                                       Trona-containing Waste Rock; Sample 1                                          10 × 20 mesh                                                             conductive stream                                                                         86.4   41.7         93.8 44.6 6.2  21.2                             magnetic stream                                                                           2.0    1.0          67.3 0.7  32.7 2.6                              non-conductive/                                                                           11.6   5.6    24.6  69.5 4.4  30.5 14.0                             non-magnetic                                                                   stream                                                                         Total      100.0  48.3         90.5 49.8 9.5  37.7                             20 × 35 mesh                                                             conductive stream                                                                         56.9   12.1         91.9 12.6 8.1  8.0                              magnetic stream                                                                           9.5    2.0          83.6 1.9  16.4 2.7                              non-conductive/                                                                           33.6   7.1    31.3  83.2 6.8  16.8 9.8                              non-magnetic                                                                   stream                                                                         Total      100.0  21.2         88.2 21.3 11.8 20.5                             35 × 65 mesh                                                             conductive stream                                                                         28.6   3.9          91.5 4.1  8.5  2.7                              magnetic stream                                                                           19.1   2.6          87.0 2.6  13.0 2.8                              non-conductive/                                                                           52.2   7.1    31.3  85.3 6.9  14.7 8.6                              non-magnetic                                                                   stream                                                                         Total      100.0  13.6         87.4 13.6 12.6 14.1                             65 × 150 mesh                                                            conductive stream                                                                         50.8   3.7          87.8 3.7  12.2 3.7                              magnetic stream                                                                           8.9    0.7          82.7 0.6  17.3 0.9                              non-conductive/                                                                           40.3   2.9    12.9  77.4 2.6  22.6 5.4                              non-magnetic                                                                   stream                                                                         Total      100.0  7.3          83.2 6.9  16.8 10.0                             Minus 150 mesh    9.6          77.4 8.4  22.6 17.7                             Plus 65 mesh trona                                                                               19.9         80.1 18.1 19.9 32.4                             Trona Prod.,      22.8   100.0 79.7 20.7 20.3 37.8                             Calc.                                                                          Trona +           32.4         79.0 29.2 21.0 55.5                             minus                                                                          150 Calc.                                                                      Sample Calc.      100.0        87.8 100.0                                                                               12.2 100.0                            Heavy Liquid Density Separation of Plus 65 Mesh                                Non-Magnetic/Non-Conductive Sample 1                                           <2.0 S.G.  0.2    0.0          --   --   --   --                               2.0 × 2.3 S.G.                                                                      19.0   3.8          3.4  0.1  96.6 29.8                             >2.3 S.G.  80.8   16.1         98.3 18.0 1.7  2.5                              Total      100.0  19.9         80.1 18.1 19.9 32.4                             ______________________________________                                    

                  TABLE 2                                                          ______________________________________                                                  Weight Percent                                                                       Bene- Assay                                                              Frac-                                                                               Sam-   ficiated                                                                               Insoluble                                                                              Soluble                                   Fraction   tion   ple    Product                                                                              %    Distr.                                                                              %    Distr.                           ______________________________________                                         Electrostatic and Magnetic Separation of                                       Trona-containing Waste Rock; Sample 2                                          10 × 20 mesh                                                             conductive stream                                                                         57.6   27.6         87.7 40.9 12.3 8.3                              magnetic stream                                                                           3.7    1.8          68.1 2.0  31.9 1.4                              non-conductive/                                                                           38.7   18.6   49.4  19.1 6.0  80.9 36.9                             non-magnetic                                                                   stream                                                                         Total      100.0  47.9         60.4 48.9 39.6 46.6                             20 × 35 mesh                                                             conductive stream                                                                         30.0   3.7          81.3 5.0  18.7 1.7                              magnetic stream                                                                           15.9   2.0          62.9 2.1  37.1 1.8                              non-conductive/                                                                           54.1   6.6    17.7  46.7 5.2  53.3 8.7                              non-magnetic                                                                   stream                                                                         Total      100.0  12.3         59.6 12.4 40.4 12.2                             35 × 65 mesh                                                             conductive stream                                                                         45.8   9.1          82.8 12.8 17.2 3.9                              magnetic stream                                                                           13.5   2.7          69.3 3.2  30.7 2.0                              non-conductive/                                                                           40.7   8.1    21.6  47.7 6.5  52.3 10.4                             non-magnetic                                                                   stream                                                                         Total      100.0  20.0         66.7 22.5 33.3 16.3                             65 × 150 mesh                                                            conductive stream                                                                         22.0   1.6          82.9 2.2  17.1 0.7                              magnetic stream                                                                           20.1   1.5          74.3 1.8  25.7 0.9                              non-conductive/                                                                           57.9   4.2    11.2  42.0 3.0  58.0 6.0                              non-magnetic                                                                   stream                                                                         Total      100.0  7.3          57.5 7.1  42.5 7.6                              Minus 150 mesh    12.5         43.6 9.2  56.4 17.3                             Plus 65 mesh      33.4         31.6 17.8 68.4 56.0                             trona                                                                          Trona Prod., Calc.                                                                               37.6   100.0 32.7 20.8 67.3 62.0                             Trona + minus     50.1         35.5 30.0 64.5 79.3                             150 Calc.                                                                      Sample Calc.      100.0        59.2 100.0                                                                               40.8 100.0                            Heavy Liquid Density Separation of Plus 65 Mesh                                Non-Magnetic/Non-Conductive Sample 2                                           <2.0 S.G.  6.0    2.0          --   --   --   --                               2.0 × 2.3 S.G.                                                                      63.0   21.0         4.7  1.7  95.3 49.1                             >2.3 S.G.  31.0   10.3         92.3 16.1 7.7  6.9                              Total      100.0  33.4         31.6 17.8 68.4 56.0                             ______________________________________                                    

                  TABLE 3                                                          ______________________________________                                                  Weight Percent                                                                       Bene- Assay                                                              Frac-                                                                               Sam-   ficiated                                                                               Insoluble                                                                              Soluble                                   Fraction   tion   ple    Product                                                                              %    Distr.                                                                              %    Distr.                           ______________________________________                                         Electrostatic and Magnetic Separation of                                       Trona-Containing Waste Rock; Sample 3                                          10 × 20 mesh                                                             conductive stream                                                                         26.1   13.2         30.1 50.8 69.9 10.0                             magnetic stream                                                                           4.4    2.2          4.6  1.3  95.4 2.3                              non-conductive/                                                                           69.5   35.2   58.8  2.4  10.8 97.6 37.3                             non-magnetic                                                                   stream                                                                         Total      100.0  50.6         9.7  63.0 90.3 49.6                             20 × 35 mesh                                                             conductive stream                                                                         24.9   4.0          25.0 12.7 75.0 3.2                              magnetic stream                                                                           5.8    0.9          5.6  0.7  94.4 1.0                              non-conductive/                                                                           69.3   11.1   18.5  3.0  4.3  97.0 11.7                             non-magnetic                                                                   stream                                                                         Total      100.0  16.0         8.6  17.7 91.4 15.9                             35 × 65 mesh                                                             conductive stream                                                                         12.3   1.3          21.3 3.7  78.7 1.1                              magnetic stream                                                                           4.0    0.4          6.6  0.4  93.4 0.4                              non-conductive/                                                                           83.7   9.1    15.2  4.1  4.8  95.9 9.5                              non-magnetic                                                                   stream                                                                         Total      100.0  10.9         6.3  8.8  93.7 11.1                             65 × 150 mesh                                                            conductive stream                                                                         27.5   1.8          8.2  1.9  91.8 1.8                              magnetic stream                                                                           3.9    0.3          4.4  0.1  95.6 0.3                              non-conductive/                                                                           68.7   4.4    7.4   3.6  2.0  96.4 4.6                              non-magnetic                                                                   stream                                                                         Total      100.0  6.5          4.9  4.0  95.1 6.7                              Minus 150 mesh    16.0         3.2  6.6  96.8 16.8                             Plus 65 mesh trona                                                                               55.4         2.8  19.8 97.2 58.4                             Trona Prod., Calc.                                                                               59.8   100.0 2.9  21.9 97.1 63.1                             Trona + minus     75.9         2.9  28.4 97.1 79.9                             150 Calc.                                                                      Sample Calc.      100.0        7.8  100  92.2 100                              Heavy Liquid Density Separation of Plus 65 Mesh                                Non-Magnetic/Non-Conductive Sample 3                                           <2.0 S.G.  0.2    0.1          --   --   --   --                               2.0 × 2.3 S.G.                                                                      96.1   53.2         1.2  8.2  98.8 57.1                             >2.3 S.G.  3.7    2.1          44.5 11.7 55.5 1.4                              Total      100.0  55.4         2.8  19.8 97.2 58.4                             ______________________________________                                    

                  TABLE 4                                                          ______________________________________                                                  Weight Percent                                                                       Bene- Assay                                                              Frac-                                                                               Sam-   ficiated                                                                               Insoluble                                                                              Soluble                                   Fraction   tion   ple    Product                                                                              %    Distr.                                                                              %    Distr.                           ______________________________________                                         Electrostatic and Magnetic Separation of                                       Trona-containing Waste Rock; Sample 4                                          10 × 20 mesh                                                             conductive stream                                                                         11.7   6.4          11.3 22.3 88.7 5.9                              magnetic stream                                                                           6.3    3.5          3.0  3.2  97.0 3.5                              non-conductive/                                                                           82.0   45.0   68.3  1.9  26.3 98.1 45.6                             non-magnetic                                                                   stream                                                                         Total      100.0  54.8         3.1  51.8 96.9 54.9                             20 × 35 mesh                                                             conductive stream                                                                         15.4   2.2          14.3 9.5  85.7 1.9                              magnetic stream                                                                           10.8   1.5          5.4  2.5  94.6 1.5                              non-conductive/                                                                           73.8   10.3   15.7  2.6  8.3  97.4 10.4                             non-magnetic                                                                   stream                                                                         Total      100.0  14.0         4.7  20.3 95.3 13.8                             35 × 65 mesh                                                             conductive stream                                                                         18.7   1.4          11.1 4.9  88.9 1.3                              magnetic stream                                                                           2.1    0.2          10.5 0.5  89.5 0.1                              non-conductive/                                                                           79.2   6.0    9.2   3.8  7.1  96.2 6.0                              non-magnetic                                                                   stream                                                                         Total      100.0  7.6          5.3  12.5 94.7 7.5                              65 × 150 mesh                                                            conductive stream                                                                         17.9   1.1          7.0  2.3  93.0 1.0                              magnetic stream                                                                           4.4    0.3          2.5  0.2  97.5 0.3                              non-conductive/                                                                           77.7   4.6    6.9   3.0  4.2  97.0 4.6                              non-magnetic                                                                   stream                                                                         Total      100.0  5.9          3.7  6.7  96.3 5.8                              Minus 150 mesh    17.7         1.6  8.7  98.4 18.0                             Plus 65 mesh trona                                                                               61.3         2.2  41.7 97.7 66.6                             Trona Prod., Calc.                                                                               65.9   100.0 2.3  45.9 97.8 78.7                             Trona + minus     83.6         2.1  54.6 97.9 84.6                             150 Calc.                                                                      Sample Calc.      100.0        3.2  100.0                                                                               96.8 100.0                            Heavy Liquid Density Separation of Plus 65 Mesh                                Non-Magnetic/Non-Conductive Sample 4                                           <2.0 S.G.  0.4    0.0          --   --   --   --                               2.0 × 2.3 S.G.                                                                      98.6   60.5         2.0  37.3 98.0 61.2                             >2.3 S.G.  1.0    0.6          23.3 4.4  76.7 5.3                              Total      100.0  61.3         2.2  41.7 97.7 66.6                             ______________________________________                                    

                  TABLE 5                                                          ______________________________________                                                  Weight Percent                                                                       Bene- Assay                                                              Frac-                                                                               Sam-   ficiated                                                                               Insoluble                                                                              Soluble                                   Fraction   tion   ple    Product                                                                              %    Distr.                                                                              %    Distr.                           ______________________________________                                         Electrostatic and Magnetic Separation of                                       Trona-Containing Waste Rock; Sample 5                                          10 × 20 mesh                                                             conductive stream                                                                         23.0   10.9         37.8 48.0 62.2 7.4                              magnetic stream                                                                           5.2    2.5          3.8  1.1  96.2 2.6                              non-conductive/                                                                           71.9   34.2   56.2  3.0  11.9 97.0 36.3                             non-magnetic                                                                   stream                                                                         Total      100.0  47.6         11.0 61.0 89.0 46.4                             20 × 35 mesh                                                             conductive stream                                                                         21.3   3.7          25.7 11.0 74.3 3.0                              magnetic stream                                                                           10.2   1.8          5.2  1.1  94.8 1.8                              non-conductive/                                                                           68.5   11.9   19.5  3.5  4.8  96.5 12.5                             non-magnetic                                                                   stream                                                                         Total      100.0  17.3         8.4  16.9 91.6 17.4                             35 × 65 mesh                                                             conductive stream                                                                         19.8   2.2          17.0 4.4  83.0 2.0                              magnetic stream                                                                           5.9    0.7          7.4  0.6  92.6 0.7                              non-conductive/                                                                           74.3   8.4    13.8  4.6  4.5  95.4 8.7                              non-magnetic                                                                   stream                                                                         Total      100.0  11.3         7.2  9.5  92.8 11.4                             65 × 150 mesh                                                            conductive stream                                                                         19.7   1.6          11.0 2.1  89.0 1.6                              magnetic stream                                                                           3.4    0.3          3.8  0.1  96.2 0.3                              non-conductive/                                                                           76.8   6.4    10.5  4.4  3.3  95.6 6.7                              non-magnetic                                                                   stream                                                                         Total      100.0  8.3          5.7  5.5  94.3 8.6                              Minus 150 mesh    15.5         4.0  7.2  96.0 16.3                             Plus 65 mesh trona                                                                               54.5         3.4  21.2 96.5 64.3                             Trona Prod., Calc.                                                                               60.8   100.0 3.5  24.5 96.6 72.0                             Trona + minus     76.3         3.6  31.7 96.4 80.5                             150 Calc.                                                                      Sample Calc.      100          8.6  100  91.4 100                              Heavy Liquid Density Separation of Plus 65 Mesh                                Non-Magnetic/Non-Conductive Sample 5                                           <2.0 S.G.  0.3    0.2          --   --   --   --                               2.0 × 2.3 S.G.                                                                      92.6   50.4         2.5  14.6 97.5 53.8                             >2.3 S.G.  7.1    3.9          20.2 9.1  79.8 10.5                             Total      100.0  54.5         3.4  21.2 96.5 64.3                             ______________________________________                                    

                  TABLE 6                                                          ______________________________________                                                  Weight Percent                                                                       Bene- Assay                                                              Frac-                                                                               Sam-   ficiated                                                                               Insoluble                                                                              Soluble                                   Fraction   tion   ple    Product                                                                              %    Distr.                                                                              %    Distr.                           ______________________________________                                         Electrostatic and Magnetic Separation of                                       Trona-Containing Waste Rock; Sample 6                                          10 × 20 mesh                                                             conductive stream                                                                         28.3   14.1         18.0 47.7 82.0 12.2                             magnetic stream                                                                           4.4    2.2          2.8  1.1  97.2 2.2                              non-conductive/                                                                           67.3   33.4   57.3  2.1  13.2 97.9 34.5                             non-magnetic                                                                   stream                                                                         Total      100.0  49.7         6.6  62.0 93.4 49.0                             20 × 35 mesh                                                             conductive stream                                                                         17.5   2.7          21.4 10.8 78.6 2.2                              magnetic stream                                                                           6.7    1.0          3.8  0.7  96.2 1.0                              non-conductive/                                                                           75.8   11.6   19.9  3.0  6.5  97.0 11.9                             non-magnetic                                                                   stream                                                                         Total      100.0  15.3         6.3  18.1 93.7 15.1                             35 × 65 mesh                                                             conductive stream                                                                         13.0   1.1          16.2 3.5  83.8 1.0                              magnetic stream                                                                           6.0    0.5          6.7  0.7  93.3 0.5                              non-conductive/                                                                           81.0   7.1    12.3  2.8  3.8  97.2 7.3                              non-magnetic                                                                   stream                                                                         Total      100.0  8.8          4.8  7.9  95.2 8.9                              65 × 150 mesh                                                            conductive stream                                                                         16.5   1.3          6.6  1.6  93.4 1.3                              magnetic stream                                                                           4.2    0.3          3.6  0.2  96.4 0.3                              non-conductive/                                                                           79.3   6.1    10.5  2.2  2.5  97.8 6.3                              non-magnetic                                                                   stream                                                                         Total      100.0  7.7          3.0  4.3  97.0 7.9                              Minus 150 mesh    18.5         2.2  7.7  97.8 19.1                             Plus 65 mesh trona                                                                               52.1         2.4  23.5 97.6 60.1                             Trona Prod., Calc.                                                                               58.3   100.0 2.4  26.0 97.6 71.3                             Trona + minus     76.8         2.3  33.7 97.7 79.2                             150 Calc.                                                                      Sample Calc.      100.0        5.3  100.0                                                                               94.7 100.0                            Heavy Liquid Density Separation of Plus 65 Mesh                                Non-Magnetic/Non-Conductive Sample 6                                           <2.0 S.G.  0.4    0.2          --   --   --   --                               2.0 × 2.3 S.G.                                                                      98.8   51.5         2.0  19.4 98.0 53.3                             >2.3 S.G.  0.8    0.4          52.5 4.1  47.5 6.8                              Total      100.0  52.1         2.4  23.5 97.6 60.1                             ______________________________________                                    

                  TABLE 7                                                          ______________________________________                                                  Weight Percent                                                                       Bene- Assay                                                              Frac-                                                                               Sam-   ficiated                                                                               Insoluble                                                                              Soluble                                   Fraction   tion   ple    Product                                                                              %    Distr.                                                                              %    Distr.                           ______________________________________                                         Electrostatic and Magnetic Separation of                                       Trona-Containing Waste Rock; Sample 7                                          10 × 20 mesh                                                             conductive stream                                                                         0.0    0.0               0.0       0.0                              magnetic stream                                                                           15.8   5.0          34.1 16.5 65.9 3.6                              non-conductive/                                                                           84.2   26.3   34.6  9.7  24.9 90.3 26.5                             non-magnetic                                                                   stream                                                                         Total      100.0  31.3         13.6 41.3 86.4 30.2                             20 × 35 mesh                                                             conductive stream                                                                         0.0    0.0               0.0       0.0                              magnetic stream                                                                           8.0    1.7          29.3 4.8  70.7 1.3                              non-conductive/                                                                           92.0   19.3   25.3  7.7  14.5 92.3 19.9                             non-magnetic                                                                   stream                                                                         Total      100.0  21.0         9.4  19.2 90.6 21.2                             35 × 65 mesh                                                             conductive stream                                                                         0.0    0.0               0.0       0.0                              magnetic stream                                                                           11.4   2.2          23.7 5.1  76.3 1.9                              non-conductive/                                                                           88.6   17.0   22.3  6.4  10.6 93.6 17.8                             non-magnetic                                                                   stream                                                                         Total      100.0  19.2         8.4  15.7 91.6 19.6                             65 × 150 mesh                                                            conductive stream                                                                         0.0    0.0               0.0       0.0                              magnetic stream                                                                           6.5    0.9          21.1 1.9  78.9 0.8                              non-conductive/                                                                           93.5   13.6   17.8  7.6  10.0 92.4 14.0                             non-magnetic                                                                   stream                                                                         Total      100.0  14.5         8.5  12.0 91.5 14.8                             Minus 150 mesh    14.0         8.7  11.8 91.3 14.2                             Plus 65 mesh trona                                                                               62.7         8.2  49.9 91.9 78.1                             Trona Prod., Calc.                                                                               76.3   100.0 8.1  60.0 91.8 77.5                             Trona + minus     90.2         8.2  71.8 91.8 92.4                             150 Calc.                                                                      Sample Calc.      100.0        10.3 100.0                                                                               89.7 100.0                            Heavy Liquid Density Separation of Plus 65 Mesh                                Non-Magnetic/Non Conductive Sample 7                                           <2.0 S.G.  0.2    0.1          --   --   --   --                               2.0 × 2.3 S.G.                                                                      93.0   58.3         4.2  23.8 95.8 62.2                             >2.3 S.G.  6.8    4.3          63.0 26.1 37.0 15.9                             Total      100.0  62.7         8.2  49.9 91.9 78.1                             ______________________________________                                    

                  TABLE 8                                                          ______________________________________                                                  Weight Percent                                                                       Bene- Assay                                                              Frac-                                                                               Sam-   ficiated                                                                               Insoluble                                                                              Soluble                                   Fraction   tion   ple    Product                                                                              %    Distr.                                                                              %    Distr.                           ______________________________________                                         Electrostatic and Magnetic Separation of                                       Trona-Containing Waste Rock; Sample 8                                          10 × 20 mesh                                                             conductive stream                                                                         18.8   6.2          35.0 23.6 65.0 4.5                              magnetic stream                                                                           1.3    0.4          28.7 1.4  71.3 0.4                              non-conductive/                                                                           79.9   26.5   40.9  4.4  12.6 95.6 27.9                             non-magnetic                                                                   stream                                                                         Total      100.0  33.2         10.5 37.6 89.5 32.7                             20 × 35 mesh                                                             conductive stream                                                                         13.6   3.0          45.7 15.0 54.3 1.8                              magnetic stream                                                                           2.1    0.5          40.9 2.1  59.1 0.3                              non-conductive/                                                                           84.3   18.9   29.2  6.3  12.9 93.7 19.5                             non-magnetic                                                                   stream                                                                         Total      100.0  22.4         12.4 30.0 87.6 21.6                             35 × 65 mesh                                                             conductive stream                                                                         10.0   1.1          50.2 5.9  49.8 0.6                              magnetic stream                                                                           3.2    0.3          48.9 1.8  51.1 0.2                              non-conductive/                                                                           86.7   9.3    14.4  6.9  7.0  93.1 9.6                              non-magnetic                                                                   stream                                                                         Total      100.0  10.8         12.6 14.7 87.4 10.4                             65 × 150 mesh                                                            conductive stream                                                                         12.7   1.5          22.1 3.6  77.9 1.3                              magnetic stream                                                                           2.5    0.3          32.0 1.0  68.0 0.2                              non-conductive/                                                                           84.8   10.0   15.4  3.6  3.9  96.4 10.6                             non-magnetic                                                                   stream                                                                         Total      100.0  11.8         6.7  8.5  93.3 12.1                             Minus 150 mesh    21.9         3.9  9.2  96.1 23.2                             Plus 65 mesh trona                                                                               54.7         5.5  32.5 94.5 57.0                             Trona Prod., Calc.                                                                               64.7   100.0 5.2  36.4 94.8 67.6                             Trona + minus     86.6         4.9  45.6 95.1 90.8                             150 Calc.                                                                      Sample Calc.      100.0        9.2  100.0                                                                               90.8 100.0                            Heavy Liquid Density Separation of Plus 65 Mesh                                Non-Magnetic/Non-Conductive Sample 8                                           <2.0 S.G.  0.3    0.2          --   --   --   --                               2.0 × 2.3 S.G.                                                                      97.0   53.1         2.0  11.5 98.0 57.3                             >2.3 S.G.  2.7    1.5                                                          Total      100.0  54.7         5.5  32.5 94.5 57.0                             ______________________________________                                    

EXAMPLE 9

An ore sample containing trona, recovered from Bed 17 of the Green River Formation in Wyoming, was beneficiated using the process described below and the results are represented by the data in Table 9. The ore was a commercially available trona-containing material identified as T-50, available from Solvay Minerals S.A., Green River, Wyo. The T-50 material has a trona purity of about 95% and a size range of 20×150 mesh Tyler.

The ore sample was first classified using a screening process to divide the ore sample into three size fractions: +35 mesh, 35×65 mesh, and -65 mesh. After screening, the +35 mesh and 35×65 mesh fractions were each separated on an air table into three density fractions: ultra-heavy, heavy and light.

After air tabling, each of the density fractions which were air tabled, and the -65 mesh size fraction that was not air tabled, were electrostatically separated by a high tension separator. To improve trona recovery, as seen in Table 9, the light and heavy density fractions from the +35 mesh size fraction were combined and electrostatically separated together. Similarly, the light and heavy density fractions from the 35×65 mesh size fraction were electrostatically separated together. Electrostatic separation was further performed on the ultra-heavy fraction from the +35 mesh size fraction, the ultra-heavy fraction from the 35×65 mesh size fraction, and the -65 mesh size fraction that was not air tabled. Each of the above-identified electrostatic separation processes divided the sample into three electrostatic fractions: conductors, middlings, and non-conductors. The respective weights and weight percentages of each electrostatic fraction are listed in the three columns of data in Table 9, as noted above.

The non-conductors and middlings from each of the above-referenced electrostatic separation processes were individually magnetically separated utilizing an induced roll magnetic separator. The conductors from each of the electrostatic separation processes were not subjected to magnetic separation. The magnetic separation process separated each incoming sample into two fractions: magnetic and non-magnetic. The weights and weight percentages of each magnetically separated fraction are listed in the three columns of data in Table 9, as described above.

The cumulative products of the entire recovery process are represented by the data in the third column at the end of Table 9. The data represents the weight percentage of non-magnetic, non-conductor material recovered from the combined light and heavy density fractions and from the ultra-heavy density fraction. As can be seen from the Table, 91.3% of the original sample was recovered as non-magnetic, non-conductive material. The trona purity of the recovered material was determined. The trona product from the lights plus heavies had a purity of 98.2%. The trona product from the ultra-heavies, which contained the shortite, had a purity of 88.9%. Comparison of these purities illustrates the benefit of removing shortite.

                                      TABLE 9                                      __________________________________________________________________________     Density, Electrostatic and Magnetic Separation of Trona Ore, Sample 9                               Weight (g, unless                                                                      Weight Percent                                                                           Purity                                  Separation           otherwise noted)                                                                       Fraction*                                                                           Sample**                                                                            (% trona)                               __________________________________________________________________________     SCREENING                                                                      plus 35 mesh         362 lb  36.8 36.8                                         35 × 65 mesh   482 lb  49.0 49.0                                         minus 65 mesh        140 lb  14.2 14.2                                         Total                984 lb  100.0                                                                               100.0                                        AIR TABLE SEPARATIONS                                                          plus 35 mesh                                                                   Ult. Heavy           1605    4.2  1.5                                          Heavy                1814    4.7  1.7                                          Lights               34960   91.1 33.5                                         Total                38379   100.00                                                                              36.8                                         35 × 65 mesh                                                             Ult. Heavy           800     2.4  1.2                                          Heavy                1603.5  4.7  2.3                                          Lights               31560   92.9 45.5                                         Total                33963.5 100.0                                                                               49.0                                         minus 65 mesh        not air tabled                                            HIGH TENSION ELECTROSTATIC SEPARATIONS (HT)                                    plus 35 mesh air table lights + heavies                                        Cond.                190.8   7.4  2.6                                          Midd                 230.5   8.9  3.1                                          Non-Cond.            2159.5  83.7 29.5                                         Total                2580.8  100.0                                                                               35.3                                         35 × 65 mesh air table lights + heavies                                  Cond.                90.4    4.5  2.2                                          Midd                 199.3   10.0 4.8                                          Non-Cond.            1709.5  85.5 40.9                                         Total                1999.2  100.0                                                                               47.8                                         plus 35 mesh air table ultra heavies                                           Cond.                467.3   29.2 0.4                                          Midd                 188.7   11.8 0.2                                          Non-Cond.            943     59.0 0.9                                          Total                1599    100.0                                                                               1.5                                          35 × 65 mesh air table ultra heavies                                     Cond.                97      12.1 0.1                                          Midd                 106.8   13.4 0.2                                          Non-Cond.            595     74.5 0.9                                          Total                798.8   100.0                                                                               1.2                                          minus 65 mesh                                                                  Cond.                23.4    1.4  0.2                                          Midd                 96.9    6.0  0.9                                          Non-Cond.            1500.6  92.6 13.2                                         Total                1620.9  100.0                                                                               14.2                                         plus 35 mesh Non Cond. from lights + heavies                                   HI Mag.              22.6    1.0  0.31                                         HI Non Mag.          2136.0  99.0 29.19                                        Total                2158.6  100.0                                                                               29.50                                        35 × 65 mesh Non Cond. from lights + heavies                             HI Mag.              61.1    4.1  1.67                                         HI Non Mag.          1438.1  95.9 39.23                                        Total                1499.2  100.0                                                                               40.90                                        plus 35 mesh Non Cond. from ultra heavies                                      HI Mag.              11.2    1.2  0.01                                         HI Non Mag.          931.7   98.8 0.90                                         Total                942.9   100.0                                                                               0.91                                         35 × 65 mesh Non Cond. from ultra heavies                                HI Mag.              53.1    8.9  0.08                                         HI Non Mag.          541.7   91.1 0.78                                         Total                594.8   100.0                                                                               0.86                                         minus 65 mesh Non Cond.                                                        HI Mag.              59.9    3.5  0.46                                         HI Non Mag.          1649.0  96.5 12.71                                        Total                1708.9  100.0                                                                               13.17                                        plus 35 mesh HT Mid from lights + heavies                                      HI Mag.              15.6    7.8  0.25                                         HI Non Mag.          183.8   92.2 2.90                                         Total                199.4   100.0                                                                               3.15                                         35 × 65 mesh HT Mid from lights + heavies                                HI Mag.              13.8    6.0  0.29                                         HI Non Mag.          216.9   94.0 4.48                                         Total                230.7   100.0                                                                               4.77                                         minus 65 mesh HT Mid                                                           HI Mag.              11.8    12.2 0.02                                         HI Non Mag.          85.1    87.8 0.16                                         Total                96.9    100.0                                                                               0.18                                         plus 35 mesh HT Mid from ultra heavies                                         HI Mag.              7.6     4.0  0.01                                         HI Non Mag.          181.2   96.0 0.15                                         Total                188.8   100.0                                                                               0.15                                         35 × 65 mesh HT Mid from ultra heavies                                   HI Mag.              6.9     6.5  0.05                                         HI Non Mag.          100.0   93.5 0.80                                         Total                106.9   100.0                                                                               0.85                                         CUMULATIVE PRODUCTS                                                            Recovered from lights + heavies                                                Primary non mag, non conductor    81.13                                                                               98.2                                    Scav. non mag, non conductor      7.54 94.4                                    Subtotal                          88.67                                                                               98.0                                    Recovered from ultra heavies                                                   Primary non mag, non conductor    1.68 85.0                                    Scav. non mag, non conductor      0.94 95.7                                    Subtotal                          2.62 88.9                                    Total non mag, non conductor (incl. - 65 mesh)                                                                   91.30                                                                               97.7                                    Total conductor                   5.56 55.2                                    Total HI magnetics                3.14 80.3                                    Head Calc. from all test products 100.00                                                                              94.8                                    __________________________________________________________________________      *Based on feed to separation as 100%                                           **Based on original sample as 100%                                       

EXAMPLE 10

This example illustrates beneficiation of trona using air tabling, electrostatic separation and magnetic separation, and demonstrates a relationship between breadth of size fractions and effectiveness of air tabling as the density separation method by comparison with heavy liquid separation.

A sample of bulk trona from Bed 17 of the Green River Formation in Wyoming was crushed to -6 mesh. The sample was subsequently sized into size fractions of 6×10 mesh, 10×20 mesh, 20×35 mesh, 35×65 mesh (Tyler mesh). Each of the plus 65 mesh size fractions was then subjected to initial density separation on an air table (Rougher Pass). The Rougher Pass light fractions were subsequently sent through a cleaner pass and for the 6×10 mesh fraction, the heavy fraction was sent to a scavenger pass. The resulting separations are shown in Table 10.1.

Each of the size fractions was then subsequently beneficiated using either magnetic separation (in the case of 6×10 mesh fraction) or electrostatic separation and magnetic separation. The portions of material from each separation reporting to various product streams are shown in Table 10.1.

The non-magnetic, in the case of the 6×10 mesh fraction, and the non-magnetic/non-conductive fractions were then further analyzed by conducting a second density separation based on heavy liquid separation to identify what portion of impurities which are separable by density separation had not been removed in the earlier air tabling step. The results of this analysis are shown in Table 10.2. The column entitled ">2.3 S.G., %" identifies the total amount of material separated from the beneficiated ore by the additional heavy liquid density separation step. Additionally, that column shows subcolumns titled "Plus" and "Minus." These two subcolumns represent a breakdown of the "Total" percentage of material which is greater than 2.3 S.G. which falls into either the coarser or finer portion of the particular stream. For example, the 6×10 mesh fraction was broken down into a 6×8 mesh fraction and an 8×10 mesh fraction. Thus, by comparing the "Plus" and "Minus" subcolumns of the ">2.3 S.G., %," it can be seen that inefficiency in the air tabling density separation tended to be at smaller particle sizes within each size fraction because most of the higher specific gravity material left by air tabling was in the smaller particle sizes (the "Minus" subcolumn).

The columns titled "Insoluble Assay" and "Soluble Assay" provide data on the portion of each stream which is insoluble (i.e., impurity) before heavy liquid separation ("Total" subcolumn) and after heavy liquid separation ("<2.3 S.G." subcolumn). Thus, for example, the purity of products resulting from beneficiating ore using air tabling can be seen in the "Total" subcolumn of the "Soluble Assay" column for each of the different streams. This purity can be compared with the subsequent column, having a higher purity, which identifies the purity of the beneficiated material with the subsequent heavy liquid separation to indicate a theoretical purity based on perfect density separation. In addition, the improvement in trona purity between the non-magnetic/non-conductive product which was not air tabled and the non-magnetic/non-conductive product which was air tabled can be seen by comparing the "Total Non-Magnetic/Non-Conductive from Untabled Feed" line with the "Total Non-Magnetic/Non-Conductive from Cleaner Lights" line in the "Cumulative Products" section of Table 10.2.

                  TABLE 10.1                                                       ______________________________________                                         Data from Air Table Tests on Bulk Trona Sample Crushed to Minus 6              Mesh                                                                                           Weight, % of                                                   Product           Feed    Size Fraction                                                                            Sample                                     ______________________________________                                         6 × 10 MESH                                                              Rougher Pass                                                                   Heavies           17.7    17.7      7.9                                        Lights            82.3    82.3      36.7                                       Feed Calc.        100.0   100.0     44.6                                       Scavenger Pass                                                                 Heavies           2.8     3.1       0.2                                        Lights            97.2    17.2      7.7                                        Feed Calc.        100.0   20.3      7.9                                        Cleaner Pass                                                                   Heavies           1.5     1.2       0.6                                        Lights            98.5    81.1      36.2                                       Feed Calc.        100.0   82.3      36.7                                       10 × 20 MESH                                                             Rougher Pass                                                                   Heavies           7.6     7.6       0.9                                        Lights            92.4    92.4      11.4                                       Feed Calc.        100.0   100.0     12.3                                       Cleaner Pass                                                                   Heavies           2.5     2.3       0.3                                        Lights            97.5    90.1      11.1                                       Feed Calc.        100.0   92.4      11.4                                       20 × 35 MESH                                                             Rougher Pass                                                                   Heavies           7.8     7.8       1.0                                        Lights            92.2    92.2      11.3                                       Feed Calc.        100.0   100.0     12.3                                       Cleaner Pass                                                                   Heavies           6.8     6.3       0.8                                        Lights            93.2    85.9      10.6                                       Feed Calc.        100.0   92.2      11.3                                       35 × 65 MESH                                                             Rougher Pass                                                                   Heavies           3.8     3.8       0.2                                        Lights            96.2    96.2      5.4                                        Feed Calc.        100.0   100.0     5.6                                        Cleaner Pass                                                                   Heavies           0.7     0.7       0.0                                        Lights            99.3    95.5      5.3                                        Feed Calc.        100.0   96.2      5.4                                        MINUS 65 MESH (not air tabled)      25.2                                       TOTAL FEED CALC.                    100.0                                      ______________________________________                                    

                                      TABLE 10.2                                   __________________________________________________________________________     Data from Electrostatic and Induced Roll Separations on Air Table              Products                                                                       Feed Crushed to minus 6 mesh                                                                                        Insoluble                                                                             Soluble                                      Weight Percent                                                                        >2.3 S.G., %                                                                             >2.3 S.G., Dist., %                                                                      Assay, % of                                                                           Assay, % of                        Product   Feed                                                                              Sample                                                                             Plus                                                                              Minus                                                                              Total                                                                             Plus                                                                              Minus                                                                              Size                                                                              Total                                                                             <2.3 SG                                                                            Total                                                                             <2.3 SG                         __________________________________________________________________________     6 × 10 MESH                                                              Not Tabled                                                                     Mag       9.0                                                                               4.0                                                               Non Mag   91.0                                                                              40.6                                                                               0.47                                                                              0.74                                                                               1.21                                                                              100.0                                                                             100.0                                                                              100.0                                                                             3.8                                                                               2.3 96.2                                                                              97.7                            Feed Calc.                                                                               100.0                                                                             44.6                                                              Rougher Lights                                                                 Mag       12.2                                                                              4.5                                                               Non Mag   87.8                                                                              32.2                                                                               0.17                                                                              0.86                                                                               1.03                                                                              28.7                                                                              92.3                                                                               67.6                                                                              3.2                                                                               2.3 96.8                                                                              97.7                            Feed Calc.                                                                               100.0                                                                             36.7                                                              Scavenger Lights                                                               Mag       4.6                                                                               0.4                                                               Non Mag   95.4                                                                              7.3 1.02                                                                              2.26                                                                               3.28                                                                              39.3                                                                              55.3                                                                               49.0                                                                              6.7                                                                               2.4 93.3                                                                              97.6                            Feed Calc.                                                                               100.0                                                                             7.7                                                               Cleaner Lights                                                                 Mag       11.6                                                                              4.2                                                               Non Mag   88.4                                                                              32.0                                                                               0.1                                                                               0.86                                                                               0.96                                                                              16.8                                                                              91.6                                                                               62.5                                                                              3.2                                                                               2.3 96.8                                                                              97.7                            Feed Calc.                                                                               100.0                                                                             36.2                                                              10 × 20 MESH                                                             Not Tabled                                                                     Cond.     20.6                                                                              2.5                                                               Mag       1.7                                                                               0.2                                                               Non Mag/Non Cond.                                                                        77.6                                                                              9.6 0.6                                                                               1.32                                                                               1.92                                                                              100.0                                                                             100.0                                                                              100.0                                                                             5.1                                                                               3.1 94.9                                                                              96.9                            Feed Calc.                                                                               100.0                                                                             12.3                                                              Rougher Lights                                                                 Cond.     15.0                                                                              1.7                                                               Mag       2.4                                                                               0.3                                                               Non Mag/Non Cond.                                                                        82.6                                                                              9.4 0.06                                                                              0.52                                                                               0.58                                                                              9.9                                                                               38.8                                                                               29.8                                                                              3.6                                                                               3.1 96.4                                                                              96.9                            Feed Calc.                                                                               100.0                                                                             11.4                                                              Cleaner Lights                                                                 Cond.     9.9                                                                               1.1                                                               Mag       2.1                                                                               0.2                                                               Non Mag/Non Cond.                                                                        88.0                                                                              9.8 0.01                                                                              0.55                                                                               0.56                                                                              1.7                                                                               42.6                                                                               29.8                                                                              3  2.5 97 97.5                            Feed Calc.                                                                               100.0                                                                             11.1                                                              20 × 35 MESH                                                             Not Tabled                                                                     Cond.     18.2                                                                              2.2                                                               Mag       2.9                                                                               0.4                                                               Non Mag/Non Cond.                                                                        78.9                                                                              9.7 0.62                                                                              2.24                                                                               2.86                                                                              100.0                                                                             100.0                                                                              100.0                                                                             5.4                                                                               3.1 94.6                                                                              96.9                            Feed Calc.                                                                               100.0                                                                             12.3                                                              Rougher Lights                                                                 Cond.     15.8                                                                              1.8                                                               Mag       2.3                                                                               0.3                                                               Non Mag/Non Cond.                                                                        81.9                                                                              9.3 0.15                                                                              1.93                                                                               2.08                                                                              23.1                                                                              82.2                                                                               69.4                                                                              4.7                                                                               3.1 95.3                                                                              96.9                            Feed Calc.                                                                               100.0                                                                             11.3                                                              Cleaner Lights                                                                 Cond.     14.2                                                                              1.5                                                               Mag       2.8                                                                               0.3                                                               Non Mag/Non Cond.                                                                        83.0                                                                              8.8 0.1                                                                               0.71                                                                               0.81                                                                              14.6                                                                              28.8                                                                               25.7                                                                              4.4                                                                               3.1 95.6                                                                              96.9                            Feed Calc.                                                                               100.0                                                                             10.6                                                              35 × 65 MESH                                                             Not Tabled                                                                     Cond.     8.6                                                                               0.5                                                               Mag       5.5                                                                               0.3                                                               Non Mag/Non Cond.                                                                        85.9                                                                              4.8 3.18                                                                              3.09                                                                               6.27                                                                              100.0                                                                             100.0                                                                              100.0                                                                             9.2                                                                               3.5 90.8                                                                              96.5                            Feed Calc.                                                                               100.0                                                                             5.6                                                               Rougher Lights                                                                 Cond.     10.0                                                                              0.5                                                               Mag       3.2                                                                               0.2                                                               Non Mag/Non Cond.                                                                        86.8                                                                              4.7 0.45                                                                              2.44                                                                               2.89                                                                              13.8                                                                              77.0                                                                               44.9                                                                              5.3                                                                               2.6 94.7                                                                              97.4                            Feed Calc.                                                                               100.0                                                                             5.4                                                               Cleaner Lights                                                                 Cond.     13.0                                                                              0.7                                                               Mag       4.8                                                                               0.3                                                               Non Mag/Non Cond.                                                                        82.2                                                                              4.4 0.24                                                                              1.73                                                                               1.97                                                                              6.8                                                                               50.7                                                                               28.5                                                                              4.9                                                                               2.8 95.1                                                                              97.2                            Feed Calc.                                                                               100.0                                                                             5.3                                                               CUMULATIVE                                                                     PRODUCTS                                                                       Total NM/NC from                                                                            64.7          100.0                                                                             100.0                                                                              100.0                                                                             4.6                                                                               2.6 95.4                                                                              97.4                            Untabled Feed                                                                  Total NM/NC from                                                                            62.9          36.9                                                                              99.1                                                                               76.2                                                                              4.0                                                                               2.6 96.0                                                                              97.4                            Rou. + Scav.                                                                   Lights       55.6          20.7                                                                              78.1                                                                               57.0                                                                              3.7                                                                               2.6 96.3                                                                              97.4                            Total NM/NC from                                                                            54.9          11.3                                                                              58.9                                                                               41.4                                                                              3.5                                                                               2.5 96.5                                                                              97.5                            Rou. Lights                                                                    Total NM/NC from                                                               CI. Lights                                                                     __________________________________________________________________________      NOTE: The >2.3 sink products from the non mag., non cond. were screened a      intermediate mesh sizes to determine the recoveries by particle size,          i.e., the 6 × 10 m at 8 m, the 10 × 20 m at 14 m, the 20           × 35 m at 28 m, and the 35 × 65 m at 48 m.                   

EXAMPLE 11

This example illustrates beneficiation of trona using air tabling, electrostatic separation and magnetic separation, and demonstrates a relationship between breadth of size fractions and effectiveness of air tabling as the density separation method by comparison with heavy liquid separation.

A sample of bulk trona from Bed 17 of the Green River Formation in Wyoming was crushed to -10 mesh. The sample was subsequently sized into size fractions of 10 ×20 mesh, 20×35 mesh and 35×65 mesh (Tyler mesh). Each of the size fractions was then subjected to initial density separation on an air table (Rougher Pass). The size fractions were subsequently sent through a cleaner and for the 10×20 mesh fractions, a scavenger pass. The resulting separations are shown in Table 11.1.

Each of the size fractions was then subsequently beneficiated using electrostatic separation and magnetic separation. The portions of material from each separation reporting to various product streams are shown in Table 11.1.

The non-magnetic/non-conductive fractions were then further analyzed by conducting a second density separation based on heavy liquid separation to identify what portion of impurities which are separable by density separation had not been removed in the earlier air tabling step. The results of this analysis are shown in Table 11.2. The column entitled ">2.3 S.G., %" identifies the total amount of material separated from the beneficiated ore by the additional heavy liquid density separation step. Additionally, that column shows subcolumns titled "Plus" and "Minus." These two subcolumns represent a breakdown of the "Total" percentage of material which is greater than 2.3 S.G. which falls into either the coarser or finer portion of the particular stream. For example, the 10×20 mesh fraction was broken down into a 10×14 mesh fraction and an 14×20 mesh fraction. Thus, by comparing the "Plus" and "Minus" subcolumns of the ">2.3 S.G., %," it can be seen that inefficiency in the air tabling density separation tended to be at smaller particle sizes within each size fraction because most of the higher specific gravity material left by air tabling was in the smaller particle size (the "Minus" column).

The columns titled "Insoluble Assay" and "Soluble Assay" provide data on the portion of each stream which is insoluble (i.e., impurity) before heavy liquid separation ("Total" subcolumn) and after heavy liquid separation ("<2.3 S.G." subcolumn). Thus, for example, the purity of products resulting from beneficiating ore using air tabling can be seen in the "Total" subcolumn of the "Soluble Assay" column for each of the different streams. This purity can be compared with the subsequent column, having a higher purity, which identifies the purity of the beneficiated material with the subsequent heavy liquid separation to indicate a theoretical purity based on perfect density separation. In addition, the improvement in trona purity between the non-magnetic/non-conductive product which was not air tabled and the non-magnetic/non-conductive product which was air tabled can be seen by comparing the "Total Non-Magnetic/Non-Conductive from Untabled Feed" line with the "Total Non-Magnetic/Non-Conductive from Cleaner Lights" line in the "Cumulative Products" section of Table 11.2.

                  TABLE 11.1                                                       ______________________________________                                         Data from Air Table Tests on Bulk Trona Sample Crushed to Minus 10             Mesh                                                                                           Weight, % of                                                   Product           Feed    Size Fraction                                                                            Sample                                     ______________________________________                                         10 × 20 MESH                                                             Rougher Pass                                                                   Heavies           13.6    13.6      4.1                                        Lights            86.4    86.4      26.3                                       Feed Calc.        100.0   100.0     30.4                                       Scavenger Pass                                                                 Heavies           8.2     1.8       0.3                                        Lights            91.8    12.5      3.8                                        Feed Calc.        100.0   14.3      4.1                                        Cleaner Pass                                                                   Heavies           3.0     2.6       0.8                                        Lights            97.0    83.8      25.5                                       Feed Calc.        100.0   86.4      26.3                                       20 × 35 MESH                                                             Rougher Pass                                                                   Heavies           1.3     1.3       0.3                                        Lights            98.7    98.7      20.1                                       Feed Calc.        100.0   100.0     20.4                                       Cleaner Pass                                                                   Heavies           4.4     4.3       0.9                                        Lights            95.6    94.4      19.2                                       Feed Calc.        100.0   98.7      20.1                                       35 × 65 MESH                                                             Rougher Pass                                                                   Heavies           13.0    13.0      1.1                                        Lights            87.0    87.0      7.4                                        Feed Calc.        100.0   100.0     8.5                                        Cleaner Pass                                                                   Heavies           18.0    15.7      1.3                                        Lights            82.0    71.3      6.1                                        Feed Calc.        100.0   87.0      7.4                                        MINUS 65 MESH (not air tabled)      40.7                                       TOTAL FEED CALC.          100.0                                                ______________________________________                                    

                                      TABLE 11.2                                   __________________________________________________________________________     Data from Electrostatic and Induced Roll Separations on Air Table              Products                                                                       Feed Crushed to minus 10 mesh                                                                                       Insoluble                                                                             Soluble                                      Weight Percent                                                                        >2.3 S.G., %                                                                             >2.3 S.G., Dist., %                                                                      Assay, % of                                                                           Assay, % of                        Product   Feed                                                                              Sample                                                                             Plus                                                                              Minus                                                                              Total                                                                             Plus                                                                              Minus                                                                              Size                                                                              Total                                                                             <2.3 SG                                                                            Total                                                                             <2.3 SG                         __________________________________________________________________________     10 × 20 MESH                                                             Not Tabled                                                                     Cond.     24.7                                                                              7.5                                                               Mag       1.6                                                                               0.5                                                               Non Mag/Non Cond.                                                                        73.7                                                                              22.4                                                                               0.59                                                                              1.19                                                                               1.78                                                                              100.0                                                                             100.0                                                                              100.0                                                                             4.0                                                                               2.6 96.0                                                                              97.4                            Feed Calc.                                                                               100.0                                                                             30.4                                                              Rougher Lights                                                                 Cond.     16.6                                                                              4.4                                                               Mag       3.6                                                                               0.9                                                               NonMag/NonCond.                                                                          79.8                                                                              21.0                                                                               0.06                                                                              0.7 0.76                                                                              9.5                                                                               55.1                                                                               40.0                                                                              2.7                                                                               2.4 97.3                                                                              97.6                            Feed Calc.                                                                               100.0                                                                             26.3                                                              Scavenger Lights                                                               Cond.     23.1                                                                              0.9                                                               Mag       3.7                                                                               0.1                                                               Non Mag/Non Cond.                                                                        73.1                                                                              2.8 0.51                                                                              3.05                                                                               3.56                                                                              10.7                                                                              31.8                                                                               24.8                                                                              6.5                                                                               2.3 93.5                                                                              97.7                            Feed Calc.                                                                               100.0                                                                             3.8                                                               Cleaner Lights                                                                 Cond.     23.1                                                                              5.9                                                               Mag       3.7                                                                               1.0                                                               Non Mag/Non Cond.                                                                        73.1                                                                              18.6                                                                               0.02                                                                              0.63                                                                               0.65                                                                              2.8                                                                               44.1                                                                               30.4                                                                              2.5                                                                               2.3 97.5                                                                              97.7                            Feed Calc.                                                                               100.0                                                                             25.5                                                              __________________________________________________________________________

EXAMPLE 12

This example illustrates beneficiation of trona using air tabling, calcination, additional air tabling, and magnetic separation in accordance with the second aspect of the present invention.

A 25 kilogram sample of 8×10 mesh trona from air tabling, having a purity of about 86.5%, was calcined at 300° F. for 3 hours and subsequently subjected to additional air tabling. The additional air tabling rejected impurities which could not be separated by air tabling prior to calcination. The purity of the trona increased from 86.5% to 93.1% after one cleaning step of air tabling. Additional magnetic separation increased the grade to 97.8%.

EXAMPLE 13

This example illustrates the effectiveness of the second aspect of the present invention in removing halite from trona. A sample of calcined trona was mixed with halite to achieve a mixture comprising about 10% halite. Air tabling of this mixture resulted in a sharp separation yielding a virtually pure halite fraction and a calcined trona product containing less than 1% halite. 

What is claimed is:
 1. A process for recovering a saline mineral from an ore containing the saline mineral and impurities, said process comprising the steps of:(a) calcining the ore to alter the apparent density of the saline mineral; and (b) separating a first portion of impurities, said impurities having an apparent density different than that of the saline mineral in the calcined ore, from the calcined ore by density separation to produce a recovered saline mineral.
 2. A process, as claimed in claim 1, wherein the recovered saline mineral comprises trona.
 3. A process, as claimed in claim 1, wherein the first portion of impurities comprises halite.
 4. A process, as claimed in claim 1, wherein the apparent density of the first portion of impurities is greater than that of the saline mineral.
 5. A process, as claimed in claim 1, further comprising the step of separating a second portion of impurities by magnetic separation.
 6. A process, as claimed in claim 5, wherein said magnetic separation step occurs after said density separation step.
 7. A process, as claimed in claim 5, wherein the second portion of impurities is more magnetic than the saline mineral.
 8. A process, as claimed in claim 7, wherein the second portion of impurities comprise minerals selected from the group consisting of shale, complex iron silicates or iron-bearing carbonates.
 9. A process, as claimed in claim 1, wherein the purity of the recovered saline mineral is at least about 95% after said separating step.
 10. A process, as claimed in claim 9, wherein the purity of the recovered saline mineral is at least about 98% after said separating step.
 11. A process, as claimed in claim 1, further comprising, before step (b), the step of reducing a particle size of the ore.
 12. A process, as claimed in claim 1, further comprising, before step (b), the step of de-dusting the ore to recover fines.
 13. A process, as claimed in claim 1, further comprising, before step (b), the step of sizing the ore into between 3 and 10 size fractions.
 14. A process, as claimed in claim 1, wherein a maximum particle size before said separating step is about 6 mesh.
 15. A process, as claimed in claim 1, wherein a minimum particle size before said separating step is about 100 mesh.
 16. A process, as claimed in claim 1, wherein said calcining step comprises heating the ore to a temperature of at least about 120° C.
 17. A process, as claimed in claim 16, wherein said heating step occurs in a fluidized bed reactor.
 18. A process, as claimed in claim 1, wherein said density separation step comprises a process selected from the group consisting of air tabling and dry jigging.
 19. A process, as claimed in claim 18, wherein said density separation step comprises air tabling.
 20. A process, as claimed in claim 1, wherein said calcining step comprises the step of heating the saline mineral in a calcining vessel above its calcining temperature with a heat source to calcine the saline mineral, wherein said heat source is not in direct fluid communication with said saline mineral.
 21. A process for recovering trona from an ore containing trona and impurities, said process comprising the steps of:(a) reducing a particle size of the ore to a size to achieve liberation of impurities; (b) sizing the ore into between 3 and 10 size fractions; (c) calcining the ore; and (d) separating impurities comprising halite from a fraction of the calcined ore by a density separation method, the impurities having a higher apparent density than calcined trona.
 22. A process for calcining a saline mineral, said process comprising the steps of:(a) heating the saline mineral in a calcining vessel above its calcining temperature with a heat source to calcine the saline mineral, wherein said heat source is not in direct fluid communication with said saline mineral and wherein said step of heating the saline mineral produces calcining gas having water vapor; (b) removing the calcining gas from the calcining vessel through a calcining gas outlet; and (c) condensing at least a portion of water vapor from the calcining gas.
 23. A process, as claimed in claim 22, wherein the saline mineral comprises trona.
 24. A process, as claimed in claim 23, wherein said step of heating comprises the steps of:(i) heating a fluid; and (ii) bringing the heated fluid into thermal communication with the calcining vessel.
 25. A process, as claimed in claim 24, wherein said step of heating a fluid comprises the steps of:(i) combusting an energy source to produce heat and combustion gas; (ii) transferring at least a portion of the heat to the fluid; (iii) directing at least a portion of the combustion gas through a combustion gas outlet which is not in direct fluid communication with said calcining vessel.
 26. A process, as claimed in claim 25, wherein said step of heating the saline mineral produces calcining gas, and wherein said process further comprises the steps of:(d) removing the calcining gas from the calcining vessel through a calcining gas outlet; and (e) combining at least a portion of the calcining gas with at least a portion of the combustion gas.
 27. A process, as claimed in claim 22, wherein particulates are removed from the calcining gas during said condensing step.
 28. A process, as claimed in claim 22, wherein said step of condensing at least a portion of the water comprises the step of condensing water by cooling the calcining gas.
 29. A process, as claimed in claim 28, further comprising the step of:(d) cooling the condensed water, wherein said condensing step comprises bringing the cooled water into thermal communication with the calcining gas.
 30. A process, as claimed in claim 22, wherein said condensing step comprises reducing the water content of the calcining gas to less than about 50%.
 31. A process, as claimed in claim 22, wherein said condensing step comprises reducing the volume of the calcining gas by at least about 50%.
 32. A process, as claimed in claim 27, wherein said condensing step reduces the particulate content by at least about 50%.
 33. A process for recovering a saline mineral from an ore containing the saline mineral and impurities, said process comprising the steps of:(a) sizing the ore to generate a first fraction of about -65 mesh and a second fraction of about +65 mesh; and (b) separating iron from the first fraction to produce a first recovered portion comprising a recovered saline mineral.
 34. A process, as claimed in claim 33, wherein said separating step comprises a wet separation process.
 35. A process, as claimed in claim 34, wherein said wet separation process comprises the slush process.
 36. A process, as claimed in claim 33, further comprising:(c) separating a second portion of impurities from the second fraction to produce a second recovered portion; and (d) combining the first recovered portion with the second recovered portion to produce a recovered saline mineral.
 37. A process, as claimed in claim 33, further comprising, before step (a), the step of reducing a particle size of said ore before said separating steps.
 38. A process, as claimed in claim 37, wherein said reducing step reduces to particle size of said ore to less than about 6 mesh. 